03 Engine swap question/issue
 

My 03 2.7 IMSB bit the dust and I am having a shop replace it with a 2.7 from a 05 late year without the serviceable IMSB (thanks Woody!).

The tech swapped most of the non-block parts from the 03, installed a new oil pump, AOS, rebuilt the clutch and flywheel, and mounted the replacement.

Now they can not get it to run. The engine is good (good compression, spark, and fuel) but the cam timing is off.

The tech said it would require transplanting the cams from the 03 (something about a winglet being different) or possibly a DME change or programming.

Before I continue and let the tech change the cams, approx 15 hours of shop time, I thought I would check here to see if anyone has any ideas.

I should have just sent it to Jake and did a bigger engine <sigh>....

Thanks!
John

A 2003 car would use a 7.8 DME, the 2005 car would have a 7.8.1 DME amongst other differences.

Would modifying the harness and putting it a 7.8.1 DME be a better solution than downgrading the engine?

The engine is designed to run with the components it came with, swapping the out individual parts opens an entirely new can of worms, which is why those doing transplants focus on using the newer DME. You also need to know that other systems have changed as well in two years of production, and even how they communicate is different, so you may be in for some additional work.

Here is my current engine configuration which should debunk some more Porsche you can't myths. I have a 2003 2.7 Boxster. The current motor was a 2004 3.2 from a SE. LN sleeved it in January 2012 to 3.6L. The crank was balanced, new Carrillo H Beam rods. JE high dome pistons JE rings. 12.2-1 compression ratio. 2006 Complete head except the scavenge pumps that were from the 2004 heads. The engine output 310+HP now at the wheels. The DME is the original box flashed with the 2004 SE program, for the 987 intake. With updates for the compression and a few other tweaks. The motor ran when I turned the key the first time with the 2.7 file still intact. The harness is off the 2003 2.7. NO CHANGES IN WIRING

I also am running a 2005 DMFW, Spec Stage 2 clutch set, 2005 5spd transmission. BTW these all just bolted in.

My suggestion is recheck the timming side 1 to side 2 if you can insert the cam tool on both side at top dead center side 2 needs reset.

PS: I have somewhere over 26,000 miles on the configuration and over 7,000 of that is on tracks. Pocono IMSA, WGI, NJMS, and VIR

I love empirical data ....nothing like hearing from someone who has actually done it

Any progress?

2005 saw a significant of a redesign of the engine, whereas the 2003 and 2004 are basically the same.

I expect that you already have this information from the 101 Projects book and the Pelican Parts tech article:
Could this vacuum pump note be part of the problem?

I am going to the shop on Monday to discuss this with the owner. I'll post an update as soon as I have something.

I'd suggest you contact board member Paul, if memory serves, he has had a 2005 3.6L engine running in a 1998 Boxster for some time, so he should be able to point out what he needed to do to get the combo to work.

I can suggest someone in SSL if you don't get anywhere with him. Great guy.